Creating an organization that embraces Process Excellence provides a strong foundation for a manufacturing system that gets it “right the first time.” When things do go wrong, the tools discussed in the following videos will get you quickly back on track. Are you looking to create a culture of Process Excellence? Contact us to find out how.

#1: Why Excellence Matters

Process Excellence starts with understanding that everyone has a unique and different starting point. Improvement comes from 1) improving work flows, and 2) paying attention to people. The first draws upon elements of Lean and the second draws upon brain science.

#2: Seeing Value in Process Mapping

Process Mapping makes a process visible. It communicates the means to achieve the output. From that baseline, a team can innovate changes that reduce waste and improve outcomes. Adjust the level of detail depending upon the use of the map.

#3: Complete FMEA in Less Time

Process problems could be costly. Risk Assessment is a proactive approach to prevent things from going wrong. Failure Mode and Effects Analysis (FMEA) is the leading methodology for assessing and controlling process risk. FMEA done well leads to action.

#4: What’s the Value of a Good Process Control Plan?

Process Control Plans lead to instructions to carry-out the controls that were defined in the FMEA. The best way is to measure and control the process inputs before they create defects. If the FMEA was done well, you’ll know the key process inputs.

#5: What’s the Best Way to Develop a Work Instruction?

Work Instructions define what and how repetitive work should be done to reduce problematic variation. Starting from a Process Flow, to FMEA, to Control Plan and finally the Work Instruction or Standardized Work, this document sets the process standard for people to follow.

#6: Seeing Value in PPAP

Production Part Approval Process is a best practice to validate you can consistently produce conforming parts, know how to check the process and validate that the controls are effective. Passing PPAP is a milestone that gives you the ‘thumbs up’ for mass production.

#8: How to Use SPC to Predict Problems

Statistical Process Controls (SPC) makes visible trends in variation versus the target value. An unanticipated measurement of a process parameter signals that the process has changed and you can proactively adjust or fix the process before defective parts are produced.

#9: How to Prevent Accidental Process Changes

Layered Process Auditing (LPA) is a discipline of ongoing verifications of process inputs. They take place sometimes every day, at the point where work happens, checking a few critical work elements. Involvement of all layers of management ensures accountability.

#10: What’s the Best Way to Solve Problems?

Structured Problem Solving (8D) is a method teams use to define process problems, identify the cause, and innovate and implement lasting solutions. 8D is valuable because it keeps teams on track, using facts and data, to prevent recurrence of problems.

#11: Keeping Process Improvement Alive

Continuous Improvement (C.I.) is a vital process for any organization that has repetitive activities. Steps include proactively: Gathering information, Reviewing with a team, Innovating changes and Deploying the plans. C.I. improves safety, quality and profit.

#12: What’s Important About APQP?

Advanced Product Quality Planning, or APQP, is a cross-industry best-practice for the launch of new products or services. We do APQP to minimize problems during product and process development and ensure “Right the First Time” to the customer and end-user.

#13: Overcoming Resistance to Change

Resistance to change is natural. Human beings are primarily emotional beings with brains wired to avoid change and danger. Leaders need to anticipate reactions to change, and even change their own natural instincts and actions in order to help people walk into change.